Monolithic part and method of forming the monolithic part

ABSTRACT

One example of the present disclosure relates to a monolithic part including an exterior wall and a first cavity. The first cavity includes a first aperture in communication with the exterior wall and a first inner surface defining a first shape. The first shape prevents extraction from the first cavity, via the first aperture, of a first virtual object having the first shape.

BACKGROUND

Passenger space within a vehicle, such as an aircraft, is an importantfactor pertaining to the comfort and efficiency of travel. Generally, atleast some space within, for example, a passenger cabin of the vehicle,is occupied by systems components (e.g. electrical components, hydrauliccomponents, cabin-air components, etc.) which decrease the amount ofspace in the passenger cabin that is available for passenger occupancy.

Conventionally, systems components are assembled from multiple partsthat include, for example, insulation blankets, wire stand-offs, ducts,and clamps. While multi-part assemblies are acceptable if sufficientroom is available, they may not be suitable when space is limited.Additionally, multi-part assemblies require sophisticated part-trackingsystems as well as increased amounts of dedicated storage space,part-specific tooling, and assembly resources, which may contribute tohigher manufacturing costs and longer lead times.

SUMMARY

Accordingly, a monolithic part and method of forming thereof, intendedto address the above-identified concerns, would find utility.

One example of the present disclosure relates to a monolithic partincluding an exterior wall and a first cavity. The first cavity includesa first aperture in communication with the exterior wall and a firstinner surface defining a first shape. The first shape preventsextraction from the first cavity, via the aperture, of a first virtualobject having the first shape.

One example of the present disclosure relates to a method of forming apart. The method includes additively forming an exterior wall of thepart, additively forming a first aperture in communication with theexterior wall, and additively forming a first inner surface of a firstcavity, wherein the first inner surface defines a first shape thatprevents extraction from the first cavity, via the first aperture, of afirst virtual object having the first shape.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described examples of the disclosure in general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein like reference charactersdesignate the same or similar parts throughout the several views, andwherein:

FIG. 1 is a block diagram of a monolithic part according to one aspectof the present disclosure;

FIG. 2 is a schematic perspective view of the monolithic part of FIG. 1,according to one aspect of the disclosure;

FIG. 2A is a schematic perspective view of the monolithic part of FIG.1, according to one aspect of the disclosure;

FIG. 2B is a schematic perspective sectional view of a portion of themonolithic part of FIG. 2A, according to one aspect of the disclosure;

FIG. 2C is a schematic illustration of a portion of the monolithic partof FIG. 2B, according to one aspect of the disclosure;

FIG. 3 is a schematic illustration of a portion of the monolithic partof FIG. 1, according to one aspect of the disclosure;

FIG. 4 is a schematic illustration of a portion of the monolithic partof FIG. 1, according to one aspect of the disclosure;

FIG. 5A is a schematic illustration of a portion of the monolithic partof FIG. 1, according to one aspect of the disclosure;

FIG. 5B is a schematic illustration of a portion of the monolithic partof FIG. 1, according to one aspect of the disclosure;

FIG. 5C is a schematic illustration of a portion of the monolithic partof FIG. 1, according to one aspect of the disclosure;

FIG. 6 is a schematic illustration of a portion of the monolithic partof FIG. 1, according to one aspect of the disclosure;

FIG. 7 is a block diagram of a method, according to one aspect of thedisclosure;

FIG. 8 is a flow diagram of aircraft production and service methodology;

FIG. 9 is a schematic illustration of an aircraft.

In the block diagram(s) referred to above, solid lines, if any,connecting various elements and/or components may represent mechanical,electrical, fluid, optical, electromagnetic and other couplings and/orcombinations thereof. As used herein, “coupled” means associateddirectly as well as indirectly. For example, a member A may be directlyassociated with a member B, or may be indirectly associated therewith,e.g., via another member C. Couplings other than those depicted in theblock diagrams may also exist. Dashed lines, if any, connecting thevarious elements and/or components represent couplings similar infunction and purpose to those represented by solid lines; however,couplings represented by the dashed lines may either be selectivelyprovided or may relate to alternative or optional aspects of thedisclosure. Likewise, elements and/or components, if any, representedwith dashed lines, indicate alternative or optional aspects of thedisclosure. Environmental elements, if any, are represented with dottedlines.

In the block diagram(s) referred to above, the blocks may also representoperations and/or portions thereof. Lines connecting the various blocksdo not imply any particular order or dependency of the operations orportions thereof.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth toprovide a thorough understanding of the disclosed concepts, which may bepracticed without some or all of these particulars. In other instances,details of known devices and/or processes have been omitted to avoidunnecessarily obscuring the disclosure. While some concepts will bedescribed in conjunction with specific examples, it will be understoodthat these examples are not intended to be limiting.

Reference herein to “one example” or “one aspect” means that one or morefeature, structure, or characteristic described in connection with theexample or aspect is included in at least one implementation. The phrase“one example” or “one aspect” in various places in the specification mayor may not be referring to the same example or aspect.

Unless otherwise indicated, the terms “first,” “second,” etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item.

Referring generally to FIGS. 1, 2, 2A, and 2B, and in particular to FIG.1, one example of the present disclosure relates to a monolithic part110 including an exterior wall 111 and a first cavity 112. The firstcavity 112 includes a first aperture 115A in communication with theexterior wall 111 and a first inner surface 114 defining a first shape114SH. The first shape 114SH prevents extraction from the first cavity112, via the first aperture 115A, of a first virtual object 114S havingthe first shape 114SH. For example, the first inner surface 114 of thefirst cavity 112 may define the first shape 114SH configured such thatthe first cavity 112 cannot be formed by e.g. injection molding or othermolding processes that use removable cores to form cavities. Withparticular reference to FIGS. 2, 2A, and 2B, those skilled in the artwill appreciate that the first inner surface 114 of the first cavity 112has the first shape 114SH configured such that if the first cavity 112were formed using a core having the same shape as the virtual object114S, extraction of the virtual core through the first aperture 115Awould not be possible. For example, a dimension of the first cavity 112may be larger than the corresponding dimension of the first aperture115A.

With particular reference to FIG. 2, in one aspect of the disclosure,which may include at least a portion of the subject matter of any of thepreceding and/or following examples and aspects, the first cavity 112 isa blind cavity and includes only a single aperture, i.e., the aperture115A. The blind configuration of the first cavity 112 may be utilizedwhen, for example, due to spatial constraints, the cavity cannot besimultaneously provided with both an inlet opening and a purge or ventopening. To fill a blind cavity, e.g., with an injectable substance, thesubstance must be introduced into the cavity using an application toolcapable of simultaneously injecting the substance and drawing a vacuumor otherwise allowing the air inside the cavity 112 to escape to enablethe substance to freely enter the cavity 112.

With particular reference to FIG. 2A, in one aspect of the disclosure,which may include at least a portion of the subject matter of any of thepreceding and/or following examples and aspects, the cavity 112 alsoincludes a second aperture 115B in communication with the exterior wall111. The first shape 114SH of the first inner surface 114 preventsextraction from the first cavity 112, via the first aperture 115A or thesecond aperture 115B, of the first virtual object 114S having the firstshape 114SH. Referring once again to FIGS. 2A and 2B, those skilled inthe art will appreciate that the first inner surface 114 of the firstcavity 112 has the first shape 114SH configured such that if the firstcavity 112 were formed using a core having the same shape as the virtualobject 114S, extraction of the virtual core through either of the firstaperture 115A or the second aperture 115B would not be possible. Forexample, a dimension of the first cavity 112 may be larger than thecorresponding dimensions of the first aperture 115A and the secondaperture 115B. In one example, the first aperture 115A and the secondaperture 115B may be simultaneously provided to enable the first cavity112 to be purged of air without using special tools when the cavity isbeing filled with an injectable substance. The monolithic part 110having inner surfaces and features as described herein may bemanufactured as described in further detail below.

Referring generally to FIG. 1 and in particular to FIG. 2B, in oneaspect of the disclosure, which may include at least a portion of thesubject matter of any of the preceding and/or following examples andaspects, the monolithic part 110 includes an aperture plug 116 tetheredto the exterior wall 111 adjacent the first aperture 115A. In oneexample, an aperture plug 116A may also be tethered to the exterior wall111 adjacent the second aperture 115B. In one aspect, tethers, such as atether 116T, connecting each of the aperture plugs 116, 116A to theexterior wall 111 may be severable tethers which, when severed, releasethe aperture plugs 116, 116A from the exterior wall 111 for insertioninto their respective apertures 115A and 115B for closing or otherwisesealing the first cavity 112. Manufacturing the monolithic part 110 withthe aperture plug(s) tethered to the exterior wall enables formingmultiple parts of an assembly as a single piece, thus decreasing partcount. Alternatively, tethers 116T connecting the aperture plugs 116,116A to the exterior wall 111 may have sufficient length to enableinsertion of the aperture plugs into their respective apertures withoutsevering the tethers.

With particular reference to FIGS. 1 and 3, in one aspect of thedisclosure, which may include at least a portion of the subject matterof any of the preceding and/or following examples and aspects, the firstcavity 112 contains an insulative medium 113. The insulative medium maybe any suitable medium for reducing noise, vibration, heat transfer, orother undesirable environmental phenomena that may be introduced insidea passenger cabin 101 of a vehicle 100, such as an aircraft, as will bedescribed below. In one aspect of the disclosure, which may include atleast a portion of the subject matter of any of the preceding and/orfollowing examples and aspects, the insulative medium includes aflame-retardant additive, such as for example, any suitableHalogen-containing compound or a Halogen-free compound including, butnot limited to, alumina trihydroxide and magnesium hydroxide.

Referring generally to FIGS. 1, 2A, and 2B, and in particular to FIG.2B, in one aspect of the disclosure, which may include at least aportion of the subject matter of any of the preceding and/or followingexamples and aspects, the monolithic part 110 includes a second cavity112A. The second cavity 112A includes a third aperture 115C incommunication with the exterior wall 111, a fourth aperture 115D incommunication with the exterior wall 111, and a second inner surface114A defining a second shape 114SHA (FIG. 1), where the second shape114SHA prevents extraction from the second cavity 112A, via the thirdaperture 115C or the fourth aperture 115D, of a second virtual object114SA having the second shape 114SHA. The second inner surface 114 ofthe second cavity 112A may define the second shape 114SHA configuredsuch that the second cavity 112A cannot be formed by e.g., injectionmolding or other molding processes that use removable cores to formcavities. Those skilled in the art will appreciate that the second innersurface 114A of the second cavity 112A has the second shape 114SHAconfigured such that if the second cavity 112A were formed using a corehaving the same shape as the second virtual object 114SA, extraction ofthe core through either of the third aperture 115C or the fourthaperture 115D would not be possible. In one example, the second cavity112A may be a duct for transporting any one of a number of fluids. Theduct may have a non-linear configuration, an example of which isillustrated in FIGS. 2, 2A, and 2B.

Referring generally to FIGS. 1, 5A, 5B, and 5C, and in particular toFIG. 1, in one aspect of the disclosure, which may include at least aportion of the subject matter of any of the preceding and/or followingexamples and aspects, the exterior wall 111 comprises at least oneconnecting feature 118 associated with at least one of the thirdaperture 115C and the fourth aperture 115D. With particular reference toFIGS. 5A, 5B and 5C, in one aspect of the disclosure, which may includeat least a portion of the subject matter of any of the preceding and/orfollowing examples and aspects, the at least one connecting feature isone of a flange 118A, a bell 118C, or a bead 118B. The at least oneconnecting feature 118 enables connection or joining of the secondcavity 112A of the monolithic part 110 to other monolithic parts and,alternatively or additionally, to components such as flexible hoses orrigid ducts.

Referring generally to FIGS. 2A and 2C, and in particular to FIG. 2C, inone aspect of the disclosure, which may include at least a portion ofthe subject matter of any of the preceding and/or following examples andaspects, the monolithic part 110 includes a wall having a variablethickness. For example, the exterior wall 111 or another wall of thefirst and/or second cavity 112, 112A may have a variable wall thickness,including a minimum thickness T1 and a maximum thickness T2. In oneaspect of the disclosure, which may include at least a portion of thesubject matter of any of the preceding and/or following examples andaspects, the variable thickness is between about 0.3 mm and about 3.0mm. In other aspects, the variable thickness may be increased up toabout 25 mm. However, those skilled in the art will appreciate thatmaintaining the variable thickness within the range of about 0.3 mm andabout 3.0 mm will reduce manufacturing cycle time of the monolithic part110.

With particular reference to FIG. 2A, in one aspect of the disclosure,which may include at least a portion of the subject matter of any of thepreceding and/or following examples and aspects, the wall, such as theexterior wall 111, includes the minimum thickness T1. The monolithicpart 110 includes a maximum dimension D and a rigidity factor of atleast about 0.0007, where the rigidity factor is defined by a ratio ofthe minimum thickness T1 to the maximum dimension D. The maximumdimension may be, for example, the greater of a length, a width, and aheight of the monolithic part 110. The rigidity factor greater or equalto about 0.0007 may provide the monolithic part with a structuralrigidity for, e.g., supporting wires, cabin wall panels, and fluidspassing through the monolithic part 110, while allowing the monolithicpart to be compact for installation in the confined areas of, forexample, the passenger cabin 101 (FIG. 1).

Referring generally to FIGS. 1, 2B, 3, and 4, and in particular to FIG.2B, in one aspect of the disclosure, which may include at least aportion of the subject matter of any of the preceding and/or followingexamples and aspects, the monolithic part 110 includes an integralwiring restraint 122. The integral wiring restraint 122 may enable theconnection of one or more wires to the monolithic part 110 forrestraining the one or more wires. In one aspect of the disclosure,which may include at least a portion of the subject matter of any of thepreceding and/or following examples and aspects, the monolithic part 110includes an integral mounting bracket 121. The integral mounting bracket121 may enable the connection of one monolithic part 110 to another, toother parts, and/or to a mounting surface of the vehicle 100 (FIG. 1).With particular reference to FIG. 1, in one aspect of the disclosure,which may include at least a portion of the subject matter of any of thepreceding and/or following examples and aspects, the monolithic partincludes an integral connector 119. The integral connector 119 mayenable the connection of one monolithic part 110 to another, to otherparts, and/or to a mounting surface of the vehicle 100 (FIG. 1).Referring generally to FIGS. 1 and 3 and with particular reference toFIG. 1, in one aspect of the disclosure, which may include at least aportion of the subject matter of any of the preceding and/or followingexamples and aspects, the integral connector is at least one threadedmember 119A. Referring to FIG. 3, the at least one threaded member maybe a threaded stud 119AS or a threaded aperture 119AN. These threadedmembers may enable the connection of one monolithic part 110 to another,to other parts, and/or to a mounting structure of the vehicle 100 (FIG.1). With particular reference to FIG. 4, in one aspect of thedisclosure, which may include at least a portion of the subject matterof any of the preceding and/or following examples and aspects, theintegral connector is at least one snap-fit member 119B. The at leastone snap-fit member 119B may be, e.g., a clip, a hook, or a receivertherefor and may enable the connection of one monolithic part 110 toanother, to other parts, and/or to a mounting structure of the vehicle100 (FIG. 1).

Referring to FIGS. 1 and 6, in one aspect of the disclosure, which mayinclude at least a portion of the subject matter of any of the precedingand/or following examples and aspects, the monolithic part includes anintegral anti-crush feature 117. In one aspect of the disclosure, whichmay include at least a portion of the subject matter of any of thepreceding and/or following examples and aspects, the first cavity 112includes a first wall 111A and a second wall 111B and the integralanti-crush feature 117 connects the first wall 111A and the second wall111B. In one aspect, the first wall 111A and the second wall 111B may bepart of the exterior wall 111 while in other aspects the first wall 111Aand second wall 111B may be any wall of the first cavity 112. Theintegral anti-crush feature 117 improves crush resistance of the firstcavity 112 to external loads applied to the cavity.

Referring to FIGS. 1 and 2B, in one aspect of the disclosure, which mayinclude at least a portion of the subject matter of any of the precedingand/or following examples and aspects, the monolithic part 110 includesan integral reinforcement feature 120. With particular reference to FIG.2B, in one aspect of the disclosure, which may include at least aportion of the subject matter of any of the preceding and/or followingexamples and aspects, the integral reinforcement feature 120 includes atleast one locally thickened portion 120A of the monolithic part 110. Forexample, the locally thickened portion 120A may form a protrusion or ribthat extends along any suitable (inner or outer) portion of, forexample, the exterior wall 111, the first inner surface 114 of the firstcavity 112, or the second inner surface 114A of the second cavity 112A.The locally thickened portion 120A may provide enhanced rigidity to themonolithic part.

Referring generally to FIGS. 1 and 7, and in particular to FIG. 7, oneexample of the present disclosure relates to a method of forming themonolithic part 110. The method includes additively forming the exteriorwall 111 of the monolithic part 110 (FIG. 7, Operation 700), additivelyforming the first aperture 115A in communication with the exterior wall111 (FIG. 7, Operation 705) and additively forming the first innersurface 114 of the first cavity 112 (FIG. 7, Operation 710), where thefirst inner surface 114 defines the first shape 114SH that preventsextraction from the first cavity 112, via the first aperture 115A, ofthe first virtual object 114S having the first shape 114SH. Theoperation 710 enables the monolithic part 110 to be formed with thefirst cavity 112, which could not otherwise be formed by e.g. injectionmolding or other molding processes that use removable cores to formcavities.

In one aspect of the disclosure, which may include at least a portion ofthe subject matter of any of the preceding and/or following examples andaspects, the method includes at least partially filling the first cavity112 with the insulative medium 113 (FIG. 7, Operation 730). Theinsulative medium 113 may be introduced into the first cavity 112 using,e.g., an application tool capable of simultaneously injecting thesubstance and drawing a vacuum or otherwise allowing the air inside thecavity 112 to escape to enable the substance to freely enter the cavity112.

In one aspect of the disclosure, which may include at least a portion ofthe subject matter of any of the preceding and/or following examples andaspects, the method includes additively forming the second aperture 115Bin communication with the exterior wall 111 (FIG. 7, Operation 735). Inone aspect of the disclosure, which may include at least a portion ofthe subject matter of any of the preceding and/or following examples andaspects, the first inner surface 114 defines the first shape 114SH thatprevents extraction from the first cavity 112, via the first aperture115A or the second aperture 115B, of the first virtual object 114Shaving the first shape 114SH. The second aperture 115B may be formed,e.g., to enable the first cavity 112 to be purged of air without usingspecial tools when the cavity is being filled with a substance, such asthe insulative medium 113.

In one aspect of the disclosure, which may include at least a portion ofthe subject matter of any of the preceding and/or following examples andaspects, the method includes additively forming the third aperture 115Cin communication with the exterior wall 111 (FIG. 7, Operation 715),additively forming the fourth aperture 115D in communication with theexterior wall 111 (FIG. 7, Operation 720), and additively forming thesecond inner surface 114A of the second cavity 112A (FIG. 7, Operation725), where the second inner surface 114A defines the second shape114SHA that prevents extraction from the second cavity 112A, via thethird aperture 115C or the fourth aperture 115D, of the second virtualobject 114SA having the second shape 114SHA. The operation 725 enablesthe monolithic part 110 to be formed with the second cavity 112A, whichcould not otherwise be formed by e.g. injection molding or other moldingprocesses that use removable cores to form cavities.

In one aspect of the disclosure, which may include at least a portion ofthe subject matter of any of the preceding and/or following examples andaspects, the method includes additively forming the aperture plug 116tethered to the exterior wall 111 adjacent the aperture 115A and/orapertures 115B, 115C, and 115D (FIG. 7, Operation 740). Manufacturingthe monolithic part 110 with the aperture plug(s) tethered to theexterior wall enables forming multiple parts of an assembly as a singlepiece, thus decreasing part count.

In one aspect of the disclosure, which may include at least a portion ofthe subject matter of any of the preceding and/or following examples andaspects, the method includes additively forming the monolithic part 110with the varying wall thickness (FIG. 7, Operation 745), including aminimum thickness T1 and a maximum thickness T2. In one aspect of thedisclosure, which may include at least a portion of the subject matterof any of the preceding and/or following examples and aspects, themethod further includes additively forming the integral anti-crushfeature 117 in the cavity 112 (FIG. 7, Operation 750). The operation 750enables introduction into the cavity 112 of reinforcement features whichcould not be formed in the cavity using other methods, such as injectionmolding.

In one aspect of the disclosure, which may include at least a portion ofthe subject matter of any of the preceding and/or following examples andaspects, the method includes additively forming the integralreinforcement feature 120 on the monolithic part 110 (FIG. 7, Operation755). Additively forming the integral reinforcement feature 120 mayreduce part count and reduce manufacturing and/or assembly time, whileproviding reinforcement of the monolithic part 110.

In one aspect of the disclosure, which may include at least a portion ofthe subject matter of any of the preceding and/or following examples andaspects, the method includes additively forming the monolithic part 110from a flame retardant material 110M (FIG. 7, Operation 760). Thoseskilled in the art will appreciate that flame-resistant properties ofthe monolithic part 110 may provide additional protection to theoccupants of the passenger cabin 101 (FIG. 1). In one aspect of thedisclosure, which may include at least a portion of the subject matterof any of the preceding and/or following examples and aspects, themonolithic part 110 may be constructed of a material having a Young'smodulus, also known as the tensile or elastic modulus, of about 0.007MPa to about 0.027 MPa, which indicates that the material will have anisotropic Young's modulus not less than about 3.5 gigapascal. In oneaspect of the disclosure, which may include at least a portion of thesubject matter of any of the preceding and/or following examples andaspects, the material may have a specific gravity of less than about1.4.

In one aspect of the disclosure, which may include at least a portion ofthe subject matter of any of the preceding and/or following examples andaspects, the method includes forming the monolithic part 110 by one ofstereolithography, laser sintering, fused deposition modeling,three-dimensional modeling, or laser engineered net shaping (FIG. 7,Operation 765).

Forming the monolithic part 110 as described above generates a part withintegral nested features that serve multiple functions, such as ducting,thermal insulation, acoustic insulation, wiring restraint, mounting, andconnection to various parts and support structures, thus reducingoverall part count. Additively forming the monolithic part 110 withvarying wall thickness allows to decrease the weight of the monolithicpart 110, while maintaining its strength. Furthermore, part-tracking,storage, tooling, and assembly-resource demands are decreased, thuspromoting lower manufacturing costs and shorter lead times.

The disclosure and drawing figures describing the operations of themethod(s) set forth herein should not be interpreted as necessarilydetermining a sequence in which the operations are to be performed.Rather, although one illustrative order is indicated, it is to beunderstood that the sequence of the operations may be modified whenappropriate. Accordingly, certain operations may be performed in adifferent order or simultaneously. Additionally, in some aspects of thedisclosure, not all operations described herein need be performed.

Examples of the disclosure may be described in the context of anaircraft manufacturing and service method 1100 as shown in FIG. 8 and anaircraft 1102 as shown in FIG. 9. During pre-production, illustrativemethod 1100 may include specification and design 1104 of the aircraft1102 and material procurement 1106. During production, component andsubassembly manufacturing 1108 and system integration 1110 of theaircraft 1102 take place. Thereafter, the aircraft 1102 may go throughcertification and delivery 1112 to be placed in service 1114. While inservice by a customer, the aircraft 1102 is scheduled for routinemaintenance and service 1116 (which may also include modification,reconfiguration, refurbishment, and so on).

Each of the processes of the illustrative method 1100 may be performedor carried out by a system integrator, a third party, and/or an operator(e.g., a customer). For the purposes of this description, a systemintegrator may include, without limitation, any number of aircraftmanufacturers and major-system subcontractors; a third party mayinclude, without limitation, any number of vendors, subcontractors, andsuppliers; and an operator may be an airline, leasing company, militaryentity, service organization, and so on.

As shown in FIG. 9, the aircraft 1102 produced by the illustrativemethod 100 may include an airframe 1118 with a plurality of high-levelsystems and an interior 1122. Examples of high-level systems include oneor more of a propulsion system 1124, an electrical system 1126, ahydraulic system 1128, and an environmental system 1130. Any number ofother systems may be included. Although an aerospace example is shown,the principles of the invention may be applied to other industries, suchas the automotive industry.

Apparatus and methods shown or described herein may be employed duringany one or more of the stages of the manufacturing and service method1100. For example, components or subassemblies corresponding tocomponent and subassembly manufacturing 1108 may be fabricated ormanufactured in a manner similar to components or subassemblies producedwhile the aircraft 1102 is in service. Also, one or more aspects of theapparatus, method, or combination thereof may be utilized during theproduction states 1108 and 1110, for example, by substantiallyexpediting assembly of or reducing the cost of an aircraft 1102.Similarly, one or more aspects of the apparatus or method realizations,or a combination thereof, may be utilized, for example and withoutlimitation, while the aircraft 1102 is in service, e.g., maintenance andservice 1116.

Different examples and aspects of the apparatus and methods aredisclosed herein that include a variety of components, features, andfunctionality. It should be understood that the various examples andaspects of the apparatus and methods disclosed herein may include any ofthe components, features, and functionality of any of the other examplesand aspects of the apparatus and methods disclosed herein in anycombination, and all of such possibilities are intended to be within thespirit and scope of the present disclosure.

Many modifications and other examples of the disclosure set forth hereinwill come to mind to one skilled in the art to which the disclosurepertains having the benefit of the teachings presented in the foregoingdescriptions and the associated drawings.

Therefore, it is to be understood that the disclosure is not to belimited to the specific embodiments disclosed and that modifications andother embodiments are intended to be included within the scope of theappended claims. Moreover, although the foregoing descriptions and theassociated drawings describe example embodiments in the context ofcertain illustrative combinations of elements and/or functions, itshould be appreciated that different combinations of elements and/orfunctions may be provided by alternative implementations withoutdeparting from the scope of the appended claims.

What is claimed is:
 1. A monolithic aircraft part comprising: a firstcavity defined by a first wall and comprising: a first aperture,extending through the first wall; a second aperture, extending throughthe first wall; and a first inner surface of the first wall, defining afirst shape, wherein a first object permanently having the first shapewould not be able to mechanically extracted from the first cavity, viathe first aperture or the second aperture; and a second cavity, definedby a second wall and comprising: a third aperture and a fourth aperture,wherein the second wall extends beyond the first wall to define at leastone of the third aperture and the fourth aperture; and a second innersurface of the second wall, defining a second shape, wherein a secondobject permanently having the second shape would not be able to bemechanically extracted from the second cavity, via the third aperture orthe fourth aperture; and wherein: the first cavity and the second cavityare not in communication with each other; and the first wall and thesecond wall share a common wall portion so that the second cavity ispartially contained within the first cavity; and the first cavitycomprises one or more of an aircraft fire-insulation medium or anaircraft acoustic-insulation medium; and the second cavity comprises aportion of an aircraft electrical system, aircraft hydraulic system, oran aircraft cabin environmental system.
 2. The monolithic aircraft partof claim 1, wherein: the second cavity forms an aircraft electricalsystem, an hydraulic electrical system, an aircraft cabin environmentalsystem.
 3. The monolithic aircraft part of claim 1, wherein: the wall ofthe second cavity, defining the third aperture, extends beyond the wallof the first cavity on one side of the first cavity; and the wall of thesecond cavity, defining the fourth aperture, extends beyond the wall ofthe first cavity on another side of the first cavity.
 4. The monolithicaircraft part of claim 1, wherein the first wall of the first cavity orthe second wall of the second cavity has a variable thickness.
 5. Themonolithic aircraft part of claim 1, wherein the wall of the firstcavity comprises at least one locally thickened portion that forms a ribthat extends along one or more of an outer surface of the wall of thefirst cavity, an inner surface of the wall of the first cavity, or aninner surface of the wall of the second cavity.
 6. The monolithicaircraft part of claim 1, wherein: the wall defining the first cavityhas a variable thickness that includes a minimum thickness, the exteriorwall has a rigidity factor of at least about 0.0007, and the rigidityfactor is defined by a ratio of the minimum thickness to a greater of alength, a width, or a height of the monolithic aircraft part.
 7. Themonolithic aircraft part of claim 1, further comprising an aperture plugtethered to the first wall, defining the first cavity, adjacent thefirst aperture and the second aperture.
 8. The monolithic aircraft partof claim 1, further comprising an aperture plug, tethered to the wall,defining the first cavity, adjacent each of the first aperture of thefirst cavity and the second aperture of the first cavity by respectivetethers, wherein each tether is configured to provide insertion of arespective aperture plug into a respective one of the first aperture andthe second aperture without separating a connection between therespective aperture plug and the wall through the tether.
 9. Themonolithic aircraft part of claim 1, wherein the second wall furthercomprises at least one connecting feature associated with at least oneof the third aperture and the fourth aperture.
 10. The monolithicaircraft part of claim 1, wherein: a portion of the wall of the secondcavity, defining at least one of the third aperture or the fourthaperture, extends beyond the wall of the first cavity and defines aconnecting feature, associated with a respective one of the thirdaperture or the fourth aperture, and the connecting feature isconfigured to join the second cavity to another monolithic aircraft partor to other aircraft components.
 11. The monolithic aircraft part ofclaim 10, wherein the connecting feature comprises a flange.
 12. Themonolithic aircraft part of claim 10, wherein the connecting featurecomprises a bell.
 13. The monolithic aircraft part of claim 10, whereinthe connecting feature comprises a bead.
 14. The monolithic aircraftpart of claim 1, further comprising an integral wiring restraint. 15.The monolithic aircraft part of claim 1, further comprising a wiringrestraint, additively formed with the wall defining the first cavity.16. The monolithic aircraft part of claim 1, further comprising anintegral mounting bracket, additively formed with the first walldefining the first cavity, wherein the mounting bracket is configured toconnect the monolithic aircraft part to one or more of other monolithicaircraft parts, to other aircraft components, or to a mounting surfaceof an aircraft.
 17. The monolithic aircraft part of claim 1, furthercomprising an integral connector, additively formed with the first wallthat defines the first cavity, wherein the connector is configured toconnect the monolithic aircraft part to one or more other monolithicaircraft parts, to other aircraft components, or to a mounting surfaceof an aircraft.
 18. The monolithic aircraft part of claim 17, whereinthe integral connector comprises one or more of a threaded member, athreaded aperture, or a snap-fit member.
 19. The monolithic aircraftpart of claim 1, wherein at least one of the first cavity or the secondcavity includes an integral anti-crush feature.
 20. The monolithicaircraft part of claim 1, further comprising an integral reinforcementfeature.